Article of footwear comprising a sole member with aperture patterns

ABSTRACT

An article of footwear includes an upper and a sole structure with a sole member. The sole member can be manufactured using a customized cushioning sole system. A user&#39;s foot morphology and/or preferences may be used to design the sole member. The sole member can include a column of apertures that are formed along the outer surface of the sole member.

BACKGROUND

The present embodiments relate generally to articles of footwear, and inparticular to articles with cushioning provisions and methods of makingsuch articles.

Articles of footwear generally include two primary elements: an upperand a sole structure. The upper is often formed from a plurality ofmaterial elements (e.g., textiles, polymer sheet layers, foam layers,leather, synthetic leather) that are stitched or adhesively bondedtogether to form a void on the interior of the footwear for comfortablyand securely receiving a foot. More particularly, the upper forms astructure that extends over instep and toe areas of the foot, alongmedial and lateral sides of the foot, and around a heel area of thefoot. The upper may also incorporate a lacing system to adjust fit ofthe footwear, as well as permitting entry and removal of the foot fromthe void within the upper. In addition, the upper may include a tonguethat extends under the lacing system to enhance adjustability andcomfort of the footwear, and the upper may incorporate a heel counter.

The sole structure is secured to a lower portion of the upper so as tobe positioned between the foot and the ground. In athletic footwear, forexample, the sole structure includes a midsole and an outsole. Thevarious sole structure components may be formed from a polymer foammaterial that attenuates ground reaction forces (i.e., providescushioning) during walking, running, and other ambulatory activities.The sole structure may also include fluid-filled chambers, plates,moderators, or other elements that further attenuate forces, enhancestability, or influence the motions of the foot, for example.

SUMMARY

In one aspect, the present disclosure is directed to a sole member foran article of footwear, comprising a sole member, the sole memberincluding an outer surface, and the outer surface comprising an uppersurface and a lower surface. The sole member has an interior portion,where the interior portion is disposed between the upper surface and thelower surface, as well as a forefoot region and a heel region.Furthermore, the sole member has a set of apertures, where at least oneaperture of the set of apertures is a blind-hole aperture, and whereeach aperture of the set of apertures is disposed along a portion of theouter surface of the sole member. Each aperture of the set of apertureshas a cross-sectional diameter, and at least a portion of the set ofapertures are arranged along the outer surface of the sole member tocomprise a first column of apertures. The first column of aperturesextends from the forefoot region to the heel region, and the firstcolumn of apertures includes at least a first aperture, a secondaperture disposed adjacent to the first aperture, and a third aperturedisposed adjacent to the second aperture. In addition, the firstaperture has a first cross-sectional diameter, the second aperture has asecond cross-sectional diameter, and the third aperture has a thirdcross-sectional diameter, where the first cross-sectional diameter issmaller than the second cross-sectional diameter, and where the secondcross-sectional diameter is smaller than the third cross-sectionaldiameter.

In another aspect, the present disclosure is directed to a sole memberfor an article of footwear, comprising a sole member, the sole memberincluding an outer surface, and the outer surface comprising an uppersurface and a lower surface. The sole member has a forefoot region and aheel region. Furthermore, the sole member has a set of apertures, whereeach aperture of the set of apertures is a blind-hole aperture, andwhere at least a portion of the set of apertures is disposed along aportion of the outer surface of the sole member to form a first columnof apertures. The first column of apertures extends from the forefootregion to the heel region. In addition, each aperture of the set ofapertures is associated with a cross-sectional diameter, where the sizeof a majority of the apertures comprising the first column of aperturesgenerally increases in a direction approaching a midfoot region of thesole member.

In another aspect, the present disclosure is directed to a sole memberfor an article of footwear, comprising a sole member, the sole memberincluding an outer surface, and the outer surface comprising an uppersurface and a lower surface. The sole member also has a set of pinpointapertures, where each aperture of the set of pinpoint apertures is ablind-hole aperture, and where the set of pinpoint apertures aredisposed along the outer surface of the sole member to form at least afirst distribution of apertures and a second distribution of apertures.Furthermore, the first distribution of apertures is associated with afirst density, the second distribution of apertures is associated with asecond density, and the first density is greater than the seconddensity.

In another aspect, the present disclosure is directed to a method forcustomizing a cushioning sole system for an article of footwear, themethod comprising obtaining information related to a pressuredistribution of a wearer's foot, and producing a first patterncomprising a first set of apertures arranged to form at least a firstcolumn of apertures. The method further includes generating instructionsto form the first pattern in a sole member, and executing theinstructions to form the first set of apertures in the sole member,where each aperture of the first column of apertures increases incross-sectional diameter in a direction approaching a center of the solemember.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is an isometric view of an embodiment of a cushioning elementincluding apertures;

FIG. 2 is an isometric bottom view of an embodiment of a sole membercomprising a cushioning element;

FIG. 3 is an isometric view of an embodiment of a cushioning elementincluding apertures in an unloaded state;

FIG. 4 is an isometric view of an embodiment of a cushioning elementincluding apertures experiencing deformation;

FIG. 5 illustrates an embodiment of the use of a device for obtainingthree dimensional foot data;

FIG. 6 schematically illustrates an embodiment of a virtual image ofdigitized three-dimensional foot data;

FIG. 7 schematically illustrates an embodiment of a virtual image of atemplate for a sole member;

FIG. 8 schematically illustrates an embodiment of a virtual image of acustomized sole member;

FIG. 9 is an embodiment of an influence diagram;

FIG. 10 is an isometric view of an embodiment of a sole member during aprocess of forming apertures;

FIG. 11 is an embodiment of a flow chart for a method of making a customsole member;

FIG. 12 is an isometric bottom view of an embodiment of a sole member;

FIG. 13 is a bottom view of an embodiment of a sole member;

FIG. 14 is a bottom view of an embodiment of a sole member;

FIG. 15 is a bottom view of an embodiment of a sole member;

FIG. 16 is a bottom view of an embodiment of a sole member;

FIG. 17 is a cross-section of an embodiment of a portion of a solemember;

FIG. 18 is an embodiment of a portion of an aperture in a sole member;and

FIG. 19 is a bottom view of an embodiment of a sole member.

DETAILED DESCRIPTION

FIG. 1 depicts an embodiment of a portion of a cushioning element. Acushioning element can include provisions for increasing flexibility,fit, comfort, and/or stability during deformation or use of thecushioning element or article incorporating the cushioning element. Someof the embodiments of cushioning elements as disclosed herein may beutilized in various articles of apparel. In one embodiment, thecushioning elements may be used in an article of footwear. For example,as discussed in further detail below, in one embodiment, portions of asole structure or sole member may incorporate or otherwise include acushioning element.

For consistency and convenience, directional adjectives are alsoemployed throughout this detailed description corresponding to theillustrated embodiments. The term “lateral” or “lateral direction” asused throughout this detailed description and in the claims refers to adirection extending along a width of a component or element. Forexample, a lateral direction may be oriented along a lateral axis 190 ofa foot (see FIG. 5), which axis may extend between a medial side and alateral side of the foot. Additionally, the term “longitudinal” or“longitudinal direction” as used throughout this detailed descriptionand in the claims refers to a direction extending across a length of anelement or component (such as a sole member). In some embodiments, alongitudinal direction may be oriented along longitudinal axis 180,which axis may extend from a forefoot region to a heel region of a foot(see FIG. 5). It will be understood that each of these directionaladjectives may also be applied to individual components of an article offootwear, such as an upper and/or a sole member. In addition, a verticalaxis 170 refers to the axis perpendicular to a horizontal surfacedefined by longitudinal axis 180 and lateral axis 190.

FIG. 1 depicts an embodiment of a first cushioning element (“firstelement”) 100. As shown in FIG. 1, in some embodiments, a cushioningelement can include one or more apertures 150. For purposes of thisdescription, apertures 150 are openings, apertures, holes, tunnels, orspaces that are disposed within the cushioning element. Generally,apertures 150 are initially formed along an exterior or outer surface ofthe cushioning element, and can extend any distance, and along anyorientation, through an interior portion 199 (e.g., the thickness,breadth, or width) of the cushioning element. It should be understoodthat the terms exterior or outer surface with reference to a sole memberdo not necessarily indicate whether the sole member is actually exposedto the outer elements. Instead, outer surface or exterior surface refersto the outermost, outward-facing layer of the sole member. Interiorportion 199 can be disposed between an upper surface 152, a lowersurface 154, and a sidewall in some embodiments. Throughout thespecification, it should be understood that characteristics beingdescribed as associated with a single aperture or aperture set can alsocharacterize any other aperture or aperture set that may be referred toin the various embodiments.

The embodiments described herein may also include or refer totechniques, concepts, features, elements, methods, and/or componentsfrom: (a) U.S. patent application Ser. No. 14/722,758, filed May 27,2015, titled “Article of Footwear Comprising a Sole Member withApertures,” (b) U.S. patent application Ser. No. 14/722,826, filed May27, 2015, titled “Article of Footwear Comprising a Sole Member withGeometric Patterns,” and (c) U.S. patent application Ser. No.14/722,740, filed May 27, 2015, titled “Article of Footwear Comprising aSole Member with Regional Patterns,” the entirety of each applicationbeing herein incorporated by reference.

In different embodiments, cushioning elements may comprise anythree-dimensional shape or geometry, including regular or irregularshapes. For example, cushioning elements may be substantially flat ornarrow, and/or relatively thick or wide. The geometry and dimensions ofa cushioning element can be configured for the application or exercisein which it will be used. For illustrative purposes, in FIG. 1, firstelement 100 has a generally oblong rectangular three-dimensional shape.Furthermore, for purposes of reference, as shown in FIG. 1, eachcushioning element may include an upper surface 152 and a lower surface154 that is disposed opposite of upper surface 152. In some cases, uppersurface 152 can be disposed adjacent to or joined to another component,such as an upper (see FIG. 12). In addition, in some cases, lowersurface 154 or upper surface 152 can be a ground contacting surface.However, in other cases, lower surface 154 may be disposed adjacent toanother material (such as an outsole). The cushioning elements canfurther include additional exterior-facing surfaces. For example, asshown in FIG. 1, first element has four sidewalls, including a firstside 156, a second side 157, a third side 158, and a fourth side 159.First side 156, second side 157, third side 158, and fourth side 159 mayextend between upper surface 152 and lower surface 154. In addition,cushioning elements include a thickness 140 extending between uppersurface 152 and lower surface 154 along vertical axis 170, and a width146 extending from second side 157 to fourth side 159 along lateral axis190, as well as a length 148 extending along longitudinal axis 180 fromfirst side 156 to third side 158. As noted in FIG. 1, thickness 140 mayinclude an upper portion 182 and a lower portion 184. Width 146 mayinclude a forward portion 192 and a rear portion 194. Furthermore,length 148 may include a first side portion 186 and a second sideportion 188. Upper surface 152, lower surface 154, and sidewalls asdepicted herein are associated with an outer surface of the cushioningelements.

It should be understood that other embodiments can have a fewer orgreater number of exterior surfaces, and that the cushioning elementsand the different regions of cushioning elements shown herein are forillustrative purposes only. In other embodiments, cushioning elementsmay include any contours, and may be any size, shape, thickness, ordimension, including regular and irregular shapes.

In some embodiments, apertures 150 have a rounded shape. In otherembodiments, apertures 150 may include a wide variety of othergeometries, including regular and irregular shapes. Apertures 150 mayhave a cross-sectional shape that is round, square, or triangular, forexample. In some embodiments, apertures 150 may have a variety ofgeometric shapes that may be chosen to impart specific aesthetic orfunctional properties to a cushioning element.

In some cases, apertures 150 can be provided on or through lower surface154 or upper surface 152 of the cushioning element. In other cases,apertures 150 can be provided on or through a side surface of thecushioning element. In one embodiment, apertures 150 can be provided onor through the side surfaces (for example, along first side 156, secondside 157, third side 158, and/or fourth side 159) of the cushioningelement as well as on lower surface 154 and upper surface 152 of thecushioning element.

In some embodiments, apertures 150 can provide means for decoupling orsoftening portions of a cushioning element in order to enhance itscushioning characteristics. For purposes of this disclosure, cushioningcharacteristics refer to the degree of fit, flexibility, cushioning,responsiveness, comfort, resilience, shock absorption, elasticity,and/or stability present in a portion of an element. For example, insome cases, apertures 150 can be formed in side portions and a lowerportion of a cushioning element to reduce the cross sectional profile ofthe element at particular regions and/or to facilitate increasedflexibility between various portions of the element. In one embodiment,apertures 150 can be applied to side portions and an upper portion toform regions between adjacent portions of the element that articulate orbend with respect to one another.

Thus, in the present embodiments, the operation of the cushioningelements can involve providing a material variance in the element. Thematerial variance can be accomplished by providing voids (apertures)which can comprise cut-outs through the cushioning element. As will bedescribed below with respect to FIG. 10, the cut-outs can involve aremoval of material from the element, thereby providing softer and/orcushioned regions in the portions that include the apertures.

Generally, apertures 150 can comprise various openings or holes arrangedin a variety of orientations and in a variety of locations on or throughthe cushioning element. For example, as shown in FIG. 1, in someembodiments, a first aperture set 102 may include apertures 150 thatextend in a direction generally aligned with vertical axis 170 throughthickness 140 of first element 100. In a cutaway section 104 of firstelement 100 of FIG. 1, it can be seen that the apertures of firstaperture set 102 begin along upper surface 152 and extend toward lowersurface 154. Thus, apertures 150 of first aperture set 102 include aseries of openings 142 (i.e., gaps or openings) along an exteriorsurface of first element 100. In FIG. 1, upper surface 152 comprises theexterior surface in which openings 142 (shown here as partially formedin cutaway section 104) are formed. As will be discussed further below,apertures 150 may extend from an initial hole along an exterior surfaceto form apertures of varying sizes and lengths through thickness 140 ofa cushioning element. Apertures 150 may be blind-hole apertures in someembodiments, where only one end of each of the apertures is open orexposed, while the opposite end of each of the aperture remains enclosedwithin the thickness of the element (i.e., only one end of each aperturemay be exposed on an exterior surface of the element).

In different embodiments, the number of apertures 150 comprising eachset of apertures can vary. For example, in one embodiment, firstaperture set 102 can comprise between 1 and 100 apertures, or more than100 apertures. In another embodiment, first aperture set 102 cancomprise between 40 and 70 apertures. In still other embodiments, firstaperture set 102 can include more than 100 apertures. In addition, insome embodiments, first aperture set 102 can include between 1 and 30apertures. Similarly, in some embodiments, first aperture set 102 caninclude a wide range of numbers of apertures 150. Thus, depending on thecushioning characteristics desired, there can be more apertures or fewerapertures than illustrated in any set of apertures formed in a portionof a cushioning element.

As noted above, in some embodiments, apertures 150 may extend variousdistances through a cushioning element. For example, as shown in FIG. 1,some apertures 150 of first aperture set 102 may not extend below upperportion 182 of first element 100. However, other apertures 150 mayextend further downward, below upper portion 182 and into lower portion184. For example, an aperture may extend from upper surface 152, and bedisposed at least partially within lower portion 184. It should beunderstood that the various portions can differ from that shown here andare for reference purposes only. Thus, apertures 150 can include anylength from zero to nearly the entire length, width, or height of thecushioning element (including a diagonal length). In cases where thecushioning element varies in geometry from the generally oblongrectangular shape shown in FIG. 1, apertures can be formed such thatthey extend up to the maximum length, thicknesses, breadth, or widthassociated with the cushioning element. Thus, in some embodiments, thelength of each aperture can vary with the size or dimensions of thecushioning element.

Generally, the shape of one or more apertures 150 in a cushioningelement can vary. In some cases, one or more apertures 150 may have alinear configuration or shape. In other cases, one or more apertures 150may have a nonlinear configuration or shape. In the embodiment of FIG.1, apertures 150 are shown having a generally linear shape, for example.

In different embodiments, the dimensions of one or more apertures 150relative to one another can vary. For example, referring to FIG. 1, insome embodiments, the lengths of each aperture in first aperture set 102can vary. For example, in one embodiment, apertures 150 of firstaperture set 102 may be longer than other apertures 150 of firstaperture set 102. Thus, in FIG. 1, a first aperture 110 has a smallerlength than adjacent second aperture 112. In other cases, however, thelengths of each aperture in first aperture set 102 can vary in anothermanner. First aperture 110 may have a length that is substantiallysimilar to or greater than the length of second aperture 112, forexample. Thus, each aperture can have a length that differs from thelength of other apertures, and apertures 150 located in differentportions of a cushioning element can vary in length relative to oneanother. The length of an aperture can also vary with reference tolongitudinal axis 180 and/or lateral axis 190. Some examples of thisvariety will be described further below.

Additionally, the size of each aperture can vary. For purposes of thisdescription, the size of an aperture can refer to the cross-sectionaldiameter or size of an aperture. In some cases, the volume associatedwith the interior of an aperture can be correlated with the averagecross-sectional diameter of the aperture. Referring to FIG. 1, in somecases, each aperture in first aperture set 102 can have a substantiallysimilar size (e.g., cross-sectional diameter). In other cases, two ormore apertures in first aperture set 102 can have substantiallydifferent sizes. For example, a third aperture 114 has a size that issmaller than the size of adjoining fourth aperture 116. In other cases,however, the sizes of each aperture in first aperture set 102 can varyin another manner. Third aperture 114 may have a size that issubstantially similar to or greater than the size of fourth aperture116, for example. Thus, each aperture can have a size that differs fromthe size of other apertures, and apertures 150 located in differentportions of a cushioning element can vary in size relative to oneanother. In other cases, the size of each aperture can vary with thesize of the cushioning element. It should be understood that the size ofan aperture can vary throughout a single aperture, such that one regionof an aperture is larger or smaller than another region of the sameaperture. However, in other embodiments, the size of an aperture mayremain substantially constant throughout the length of the aperture.Some examples of this variety will be described further below.

In some embodiments, apertures on different portions of a cushioningelement can be generally parallel with one another with respect toanother surface or side of the element. In some cases, aperturesextending from the same surface of a cushioning element may be generallyparallel with one another, such that they do not intersect. In otherwords, the apertures may be generally oriented in a similar direction.For example, apertures formed on lower surface 154 or upper surface 152may be similarly oriented in a direction generally aligned with verticalaxis 170. Thus, in different embodiments, apertures 150 may beassociated with approximately similar longitudinal, lateral, or verticalorientations. In other embodiments, however, apertures on the sidesurfaces may not be parallel with one another. In one example, there maybe apertures with openings 142 on first side 156 that are oriented inone direction, and apertures with openings 142 on first side 156 thatare oriented along a different direction. Furthermore, it will beunderstood that in some embodiments, only some apertures may begenerally aligned through upper portion 182, lower portion 184, firstside portion 186, second side portion 188, forward portion 192, and/orrear portion 194, while other apertures disposed throughout thecushioning element may not be aligned. Therefore it should be understoodthat while the embodiment of FIG. 1 shows apertures 150 having lengthsextending along vertical axis 170, apertures can also be oriented sothat they lie along any other direction (e.g., a horizontal, diagonal ornon-planar direction). For example, in some embodiments, apertures canform an angle less than 90 and greater than 0 degrees with respect tovertical axis 170, lateral axis 190, and/or longitudinal axis 180. Insome cases, apertures can form an angle between 30 and 60 degrees withrespect to vertical axis 170, lateral axis 190, and/or longitudinal axis180.

As a result of the inclusion of different possible configurations ofapertures 150, a cushioning element may have varying responsiveness toforces. In other words, apertures 150 can be disposed in a pattern thatcan help attenuate ground reaction forces and absorb energy, impartingdifferent cushioning characteristics to the element. In the embodimentsof FIGS. 2-4, a sequence of images representing possible responses ofthe cushioning elements under a load are shown.

For purposes of providing a contextual example to the reader, FIG. 2depicts an embodiment of a first sole member 200. In FIG. 3, a crosssection taken along the line 3-3 of FIG. 2 in first sole member 200depicts an unloaded second cushioning element (“second element”) 300.Second element 300 has a series of apertures 150 disposed along lowersurface 154 and extending through thickness 140 at varying lengths. Insome embodiments, apertures 150 may form a geometric pattern. In otherwords, apertures 150 may be arranged such that there is a predictablerise and fall to the sizes of the apertures throughout the cushioningelement. Thus, in some embodiments, apertures 150 may be “tuned” toprovide a smooth feel to the cushioning element, and improve comfort fora user. In FIG. 3, apertures 150 disposed nearer to third side 158 aresmaller than apertures 150 disposed nearer toward a center 350 of secondelement 300. Furthermore, apertures 150 disposed nearer to first side156 are also smaller than apertures 150 disposed nearer toward center350. In FIGS. 3-4, apertures 150 increase in size as they approachcenter 350 of second element 300, and then generally decrease in size asthey move further away from center 350. A regular arrangement as shownin second element 300 may provide more consistent cushioning for a userin some cases. However, it should be understood that, in otherembodiments, apertures 150 may have a random height and/or sizearrangement.

For purposes of convenience, heights are associated with differentportions of second element 300. In FIG. 3, a first height 310, a secondheight 320, and a third height 330 are identified. First height 310 isassociated with the portion of second element 300 toward first side 156,second height 320 is associated with the portion of second element 300toward center 350, and third height 330 is associated with the portionof second element 300 toward third side 158. In FIG. 3, first height310, second height 320, and third height 330 are substantially similar,such that thickness 140 is generally uniform through second element 300.

However, when second element 300 undergoes a first load 400 (representedby arrows), as shown in FIG. 4, the arrangement of apertures 150 canalter the responsiveness of the material. In FIG. 4, first load 400 isdirected upward in a direction generally aligned with vertical axis 170and distributed in a substantially constant, uniform manner over lowersurface 154 of second element 300. As second element 300 experiences theforce of first load 400, second element 300 can deform.

In some embodiments, when cushioning elements are compressed, they candeform in different ways. The deformation that occurs can be related tothe location of any apertures, and/or the size and orientation of theapertures. Thus, apertures 150 may function together within the materialof the cushioning element to provide variations in the relativestiffness, degree of ground reaction force attenuation, and energyabsorption properties of the cushioning element. These cushioningcharacteristics may be altered to meet the specific demands of theactivity for which the cushioning element is intended to be used,through the methods described herein.

When the compressive force of first load 400 is applied to secondelement 300, for example, the areas that include more apertures and/orapertures of greater size or length may deform to a greater extent thanthe portions of second element 300 that have fewer apertures and/orapertures of smaller size or length. As a result of the application offirst load 400, the aperture openings may be compressed and deformed. Inthe region disposed proximate of center 350, where the sizes of theapertures are larger relative to other apertures, the degree ofdeformation is greater. In the regions nearest third side 158 and firstside 156, where there are smaller sized apertures (relative to center350 of second element 300), the deformation is not as great.

In some embodiments, the deformation that occurs throughout secondelement 300 can be measurable in part by the changed shape and height ofsecond element 300 and/or the changed shape and heights of apertures150. In FIG. 4, a fourth height 410, a fifth height 420, and a sixthheight 430 can be identified. Fourth height 410 is associated with theportion of second element 300 toward first side 156, fifth height 420 isassociated with the portion of second element 300 toward center 350, andsixth height 430 is associated with the portion of second element 300toward third side 158. Thus, referring to FIGS. 3 and 4, in response tofirst load 400, the overall height of second element 300 is less.Specifically, fourth height 410 is less than first height 310, fifthheight 420 is less than second height 320, and sixth height 430 is lessthan third height 330. Furthermore, the heights across second element300 can differ, such that thickness 140 is generally non-uniform throughsecond element 300. In other words, various contours can be formed alongupper surface 152 where first load 400 has been applied.

The contours may vary in a manner generally corresponding to thearrangement of apertures 150 disposed in second element 300 in someembodiments. Thus, if apertures 150 are arranged in a repeating pattern,as seen with the apertures associated with first side 156 and theapertures associated with third side 158, which are arranged in a“mirrored” configuration, the deformation that occurs can be similarlymirrored, and the change in height may also reflect this mirroring.Thus, while fifth height 420 is less than either fourth height 410 orsixth height 430, fourth height 410 and sixth height 430 may besubstantially similar. In other words, while some areas can be providedwith different cushioning properties relative to other areas, there mayalso be areas that are provided with similar cushioning properties.

In some embodiments, the shape or orientation of the apertures may alsochange as a result of an applied force. Depending on the magnitude andthe direction of the force(s) applied, the changes in area or shape mayvary. For example, referring to FIG. 4, in one embodiment, secondelement 300 may be exposed to a force or load whereby apertures becomedeformed not only by becoming more compact, but also by curling orotherwise becoming increasingly non-linear and/or irregular. In oneembodiment, the area or volume of an aperture may decrease when acompressive force is applied.

Thus, exposure to various forces may also produce a change in the shapeor geometry, size, and/or height of cushioning elements and theapertures that may be disposed within the cushioning element. It shouldbe understood that while first load 400 is shown as being generallyuniform, other loads may be non-uniform. Depending on the magnitude andthe direction of the force(s) applied, changes in area, volume,dimensions, and/or shape of the cushioning element may vary. In someembodiments, a different force may permit the cushioning element toexpand in a lateral or longitudinal direction, such that the overalllength of the element increases. In other embodiments, different forcesmay alter the responses of the cushioning element.

It should be noted that the various degrees of deformation described andshown here are for purposes of illustration. In some situations thecushioning element may not undergo compression to the extent depicted,or may deform more or less, depending on various factors such as thematerials used in the production of the cushioning element, as well asits incorporation in other objects or articles. For example, if acushioning element is joined or attached to a less reactive material,the compressive and/or expansive properties described herein may differ,or be limited. In some embodiments, when the cushioning element isjoined to a strobel or other structure, the capacity of expansion maydecrease. In some embodiments, the perimeter of the cushioning elementmay be fixed, e.g., bonded to a strobel layer or another sole layer.However, in such embodiments, the cushioning characteristics of thecushioning element may still facilitate increased flexibility andcushioning.

Furthermore, it should be understood that while second element 300 mayexperience various forces and deformation, the deformation may beelastic. In other words, once the load is removed or decreased, thecushioning element may recover and return to its original dimensionsand/or shape, or to dimensions and/or a shape substantially similar tothe original, unloaded configuration.

As noted above, the cushioning elements described herein may be utilizedwith various components or articles. For example, the degree ofelasticity, cushioning, and flexibility of a sole component such as asole member can be important factors associated with comfort and injuryprevention for an article of footwear. FIGS. 5-8 depict an embodiment ofa method of designing a customized sole member for an article offootwear.

FIG. 5 shows the three-dimensional shape of a plantar surface 502 of afoot 500 being measured using a data collection apparatus 528. In somecases, data collection apparatus 528 can be a force platform. In othercases, data collection apparatus 528 can comprise one of thecommercially available systems for measuring plantar pressure (e.g.,Emed sensor platform, Pedar insole system, F-Scan system, Musgravefootprint system, etc.). Plantar pressure measurement systems canprovide a means of obtaining specialized information regarding a footthat can be used to customize footwear for individuals. In someembodiments, the magnitude of pressure can be determined by dividing themeasured force by the known area of the sensor or sensors evoked whilethe foot was in contact with the supporting surface in some embodiments.

For purposes of reference, foot 500, representations of foot 500,components associated with foot 500 (such as an article of footwear, anupper, a sole member, a computer aided design of foot 500, and othercomponents/representations) may be divided into different regions. Foot500 may include a forefoot region 504, a midfoot region 506 and a heelregion 508. Forefoot region 504 may be generally associated with thetoes and joints connecting the metatarsals with the phalanges. Midfootregion 506 may be generally associated with the metatarsals of a foot.Heel region 508 may be generally associated with the heel of a foot,including the calcaneus bone. In addition, foot 500 may include alateral side 510 and a medial side 512. In particular, lateral side 510and medial side 512 may be associated with opposing sides of foot 500.Furthermore, both lateral side 510 and medial side 512 may extendthrough forefoot region 504, midfoot region 506, and heel region 508. Itwill be understood that forefoot region 504, midfoot region 506, andheel region 508 are only intended for purposes of description and arenot intended to demarcate precise regions of foot 500. Likewise, lateralside 510 and medial side 512 are intended to represent generally twosides of foot 500, rather than precisely demarcating foot 500 into twohalves.

Furthermore, in the examples depicted in FIGS. 5 and 6, foot 500 and/ora virtual scan 600 of a foot may include a medial arch area 520,associated with an upward curve along medial side 512 of midfoot region506, and a lateral arch area 522, associated with an upward curve alonglateral side 510 of midfoot region 506. The region corresponding tolateral arch area 522 is best seen in FIG. 6, which illustrates acomputer screen or virtual image of digitized three-dimensional footdata. As described below, the curvature of medial arch area 520 andlateral arch area 522 may vary from one foot to another. In addition,foot 500 includes a transverse arch 524 that extends along lateral axis190 near forefoot region 504 along plantar surface 502. Foot 500 alsoincludes a heel prominence 526, which is the prominence located in heelregion 508 of foot 500. As shown in FIG. 5, foot 500 is illustrated as aleft foot; however, it should be understood that the followingdescription may equally apply to a mirror image of a foot or, in otherwords, a right foot.

Although the embodiments throughout this detailed description depictcomponents configured for use in athletic articles of footwear, in otherembodiments the components may be configured to be used for variousother kinds of footwear including, but not limited to: hiking boots,soccer shoes, football shoes, sneakers, running shoes, cross-trainingshoes, rugby shoes, basketball shoes, baseball shoes as well as otherkinds of shoes. Moreover, in some embodiments, components may beconfigured for various kinds of non-sports related footwear, including,but not limited to: slippers, sandals, high heeled footwear, loafers aswell as any other kinds of footwear.

Components associated with an article of footwear are generally made tofit various sizes of feet. In the embodiments shown, the variousarticles are configured with approximately the same footwear size. Indifferent embodiments, the components could be configured with anyfootwear sizes, including any conventional sizes for footwear known inthe art. In some embodiments, an article of footwear may be designed tofit the feet of a child. In other embodiments, an article of footwearmay be designed to fit the feet of an adult. Still, in otherembodiments, an article of footwear may be designed to fit the feet of aman or a woman.

Referring to FIGS. 5 and 6, a first step of the present method is tocollect data related to foot 500, such as using a barefoot pressuremeasurement or other data, from the foot being measured on datacollection apparatus 528. Data collection apparatus 528 may includeprovisions for capturing information about an individual's feet.Specifically, in some embodiments, data collection apparatus 528 mayinclude provisions to capture geometric information about one or morefeet. This geometric information can include size (e.g., length, widthand/or height) as well as three-dimensional information corresponding tothe customer's feet (e.g., forefoot geometry, midfoot geometry, heelgeometry and ankle geometry). In at least one embodiment, the capturedgeometric information for a customer's foot can be used to generate athree-dimensional model of the foot for use in later stages ofmanufacturing. In particular, the customized foot information caninclude at least the width and length of the foot. In some cases, thecustomized foot information may include information about thethree-dimensional foot geometry. Customized foot information can be usedto create a three-dimensional model of the foot. Embodiments may includeany other provisions for capturing customized foot information. Thepresent embodiments could make use of any of the methods and systems forforming an upper disclosed in Bruce, U.S. patent application Ser. No.14/565,582, filed Dec. 10, 2014, titled “Portable Manufacturing Systemfor Articles of Footwear,” the entirety of which is herein incorporatedby reference.

Some embodiments could use any of the systems, devices, and methods forimaging a foot as disclosed in Leedy et al., U.S. Patent PublicationNumber 2013/0258085, published Oct. 3, 2013, and titled “Foot Imagingand Measurement Apparatus,” (previously U.S. patent application Ser. No.13/433,463, filed Mar. 29, 2012), the entirety of which is hereinincorporated by reference.

In FIG. 6, a screen 602 displays virtual scan 600 of plantar pressuredistributions for foot 500. Scan 600 may provide a measured foot imageor representation, including various distinct regions to indicate thepressures applied or experienced by foot 500 over its plantar surface502. In one example, pressures can include a first pressure area 604, asecond pressure area 606, a third pressure area 608, a fourth pressurearea 610, and a fifth pressure area 612. An additional pressure area 614is indicated where plantar surface 502 did not make an impressionablecontact with the surface of data collection apparatus 528. In someembodiments, colors (not shown in FIG. 6) can be included in scan 600 tomore readily distinguish variations within the measured pressure data.It should be noted that in other embodiments, different, fewer, or morepressure areas may be measured or indicated.

As seen in FIG. 6, in some embodiments, the data collected may includescan 600 of foot 500. In some embodiments, scan 600 may be used toassess the three-dimensional shape and obtain digital data in atwo-dimensional or a three-dimensional reference frame. In otherembodiments, scan 600 can provide a baseline shape for a footwearcomponent. In one embodiment, three-dimensional scanned images may beused to measure the overall shape of a person's feet, and obtaintwo-dimensional measurements such as an outline, length, and width offoot 500. Obtaining foot geometry can establish a baseline record forthe person in one embodiment. In some embodiments, other input may alsobe provided to supplement information regarding the person beingmeasured. In different embodiments, additional data such as toe heightinformation may also be obtained. In other embodiments, plaster casts ofa person's foot may be taken and digitized. Additionally, other digitalor imaging techniques which may be employed to capture two andthree-dimensional foot shape and profile can be used to construct and/orsupplement scan 600. In other embodiments, the person whose foot isbeing measured may provide answers to questions describing the person'sphysical characteristics, limitations, preferences, and/or personallifestyle, which may impact design of the various parts describedherein.

In different embodiments, a sole member may provide one or morefunctions for an article of footwear. In FIG. 7, an image of a templateof a sole member 700 is displayed on a screen 702. In some embodiments,sole member 700 may attenuate ground reaction forces when compressedbetween the foot and the ground and/or an outsole during walking,running or other ambulatory activities. The configuration of sole member700 may vary significantly in different embodiments to include a varietyof conventional or non-conventional structures. In some cases, theconfiguration of sole member 700 can be selected or customized accordingto one or more types of ground surfaces on which sole member 700 may beused. Examples of ground surfaces include, but are not limited to:natural turf, synthetic turf, dirt, as well as other surfaces.

Upon obtaining measurements of foot 500 (see FIG. 5), sole member 700may be adjusted or altered in different embodiments. As seen in thevirtual representation depicted in FIG. 8, using the data collected fromthe steps above, a first custom sole 800 may be designed. In someembodiments, the design may utilize an application of an integratedcomputer aided design such as a computer automated manufacturing(CAD-CAM) process. Sole member 700, or any other template previouslyselected, may be provided as an input to the computer design program. Inone embodiment, the three dimensional foot shape data from scan 600 inFIG. 6 is also provided to the program.

In different embodiments, scan 600 may provide information regardingfoot shape and pressure to allow appropriate fit and comfort within thearticle of footwear. The information may be used to form first customsole 800. In some embodiments, data from scan 600 may be superimposed orotherwise incorporated into the template of sole member 700 (see FIGS. 6and 7). For example, there may be a process of aligning the datarepresenting the plantar pressures of foot 500 with sole member 700 andgenerating a partial or complete design of first custom sole 800. In oneembodiment, pressure contour lines 806 may be generated during design offirst custom sole 800. The pressure distribution may be adjusted to a‘best-fit’ position based upon user input in some embodiments. Once thedistribution is finalized, a resiliency profile may be created. Forpurposes of this disclosure, a resiliency profile is a personalizedpressure distribution for a user that may include the data collectedduring the steps described above. In some embodiments, the resiliencyprofile may be utilized in the production of first custom sole 800.Thus, in one embodiment, after the resiliency profile comprising anindividual's plantar pressure distributions is aligned with the templateof sole member 700, a customized sole member may be formed ormanufactured.

It should be understood that, in different embodiments, the design of asole member may include various modifications. Customized modificationsmay provide individual users with a wider range of comfort and fit. Forexample, different users may have differences in the height of the archof foot 500. As described above, foot 500 may include multiple arches.Generally, the arch is a raised curve on the bottom surface of foot 500.When the tendons of foot 500 pull a normal amount, foot 500 generallyforms a moderate or normal arch. However, when tendons do not pulltogether properly, there may be little or no arch. This is called “flatfoot” or fallen arch. Over-pronation of a foot may be common for thosewith flat feet. The framework of a foot can collapse, causing the footto flatten and adding stress to other parts of the foot. Individualswith flat feet may need orthotics to control the flattening of the foot.Moreover, the opposite may also occur, though high foot arches are lesscommon than flat feet. Without adequate support, highly arched feet tendto be painful because more stress is placed on the section of the footbetween the ankle and toes. This condition can make it difficult to fitinto shoes. Individuals who have high arches usually need foot support.It should be noted that such variations in arch height are one of manypossible examples of customized foot geometry that may be incorporatedinto a design.

Referring to FIG. 9, an embodiment of an influence diagram 900 isdepicted. Influence diagram 900 reflects some of the factors orvariables that can be considered, incorporated, and/or used during thegeneration of the resiliency profile, permitting customization ofcushioning characteristics 950 of a sole member. For example, a firstfactor 910 includes an individual's measured plantar pressure for eachfoot, which was discussed above with respect to FIG. 5-6. In addition, asecond factor 920 may include the materials that will be used to formthe custom sole member. A third factor 930 can be the individual user'sown personal preferences regarding the type or level of cushioningdesired. A fourth factor 940 may be the activity or sport that the userwill be generally engaging in while using the custom sole member. Insome cases, the sole member can be designed or tailored to providespecial cushioning in areas or regions of the sole member that typicallyexperience more force or pressure from the foot during specificactivities. Thus, in some embodiments, one or more of these factors cancontribute to cushioning characteristics 950 of a sole member. It shouldbe understood that influence diagram 900 is provided as an example, andmany other factors not listed here may be included in other embodiments.Furthermore, one or more factors listed in influence diagram 900 may beremoved from consideration depending on the desired output or the goalof the custom sole member.

Once a design has been generated, as with first custom sole 800, thesole member may be manufactured. In some embodiments, the modificationsmay include regions of the sole member with apertures 150 disposed alongdifferent portions of the sole member. In some embodiments, a solemember can be molded in a manner that creates apertures in the solemember. An article of footwear including apertures can be formed in anymanner. In some embodiments, apertures can be created in a sole memberusing any known methods of cutting or drilling. For example, in oneembodiment, apertures can be created using laser cutting techniques.Specifically, in some cases, a laser can be used to remove material froma sole member in a manner that forms apertures in the sole member. Inanother embodiment, a hot knife process could be used for formingapertures in a sole member. Examples of methods for forming apertures ona sole member are disclosed in McDonald, U.S. Pat. No. 7,607,241, issuedOct. 27, 2009, titled “Article of Footwear with an Articulated SoleStructure,” (previously U.S. patent application Ser. No. 11/869,604,filed Oct. 9, 2007), the entirety of which is hereby incorporated byreference. In other embodiments, however, any other type of cuttingmethod can be used for forming apertures. Furthermore, in some cases,two or more different techniques can be used for forming apertures. Asan example, in another embodiment, apertures disposed on a side surfaceof a sole member can be formed using laser cutting, while apertures on alower surface of the sole member could be formed during a moldingprocess. Still further, different types of techniques could be usedaccording to the material used for a sole member. For example, lasercutting may be used in cases where the sole member is made of a foammaterial.

In FIG. 10, a figure depicting an embodiment of a method of formingfirst custom sole 800, including apertures, is shown. Referring to FIG.10, apertures 150 can be applied to or formed in first custom sole 800using a laser drill 1000. In one embodiment, laser drill 1000 may beused to cut away or remove material through thickness 140 of firstcustom sole 800. In other cases, there may be a greater number of laserdrills used. In FIG. 10, a group of apertures are being formed alonglower surface 154 of first custom sole 800. It can be seen thatapertures have also been previously formed by laser drill 1000.

Although only apertures over one surface are shown being drilled in thisexample, it will be understood that a similar method could be used forcreating or forming apertures in any other region of first custom sole800. It should further be understood that laser drill 1000 may includeprovisions for moving along different directions in order to direct thelaser beam to the desired location. Furthermore, the sole member may bedisposed such that it may be automatically or manually moved to receivea laser 1070 at the appropriate or desired location, such as alongforefoot region 504, midfoot region 506, and/or heel region 508. Inaddition, while only one laser drill 1000 is shown in use in FIG. 10, inother embodiments, two, three, four or more laser drills may be engagedwith the sole member.

In some embodiments, referring to a magnified area 1050, it can be seenthat laser 1070 may contact lower surface 154 of first custom sole 800.When laser 1070 contacts the material, it may begin to remove materialand form a hole 1020. As laser 1070 continues to engage with thematerial of the sole member, hole 1020 may grow through thickness 140and form a first aperture 1060.

It may be recalled that each aperture may be formed such that theydiffer in one or more respects from one another, or they may be formedin a uniform manner, such that they are substantially similar in size,length, and shape. Furthermore, it should be understood that laser 1000may be oriented at an angle different from that shown in FIG. 10, sothat laser 1000 can form apertures 150 oriented in a diagonal ornon-parallel manner with respect to vertical axis 170, longitudinal axis180, and/or lateral axis 190.

Thus, as described herein, in some embodiments, the arrangement ofapertures on a sole member could be varied to tune properties of thesole member for specific types of physical or personal characteristics,and/or athletic activities, and to provide a particular local cushioningcharacteristic. For example, in some cases, the arrangement of apertureson a sole member could be selected according to the type of sport forwhich the article of footwear is intended. In some embodiments, amanufacturer could vary the arrangement of apertures for various typesof footwear, including, but not limited to, soccer footwear, runningfootwear, cross-training footwear, basketball footwear, as well as othertypes of footwear. Additionally, in other embodiments, the arrangementof apertures on a sole member could be varied according to the gender ofthe intended user. For example, in some cases, the aperture arrangementsmay vary between footwear for men and footwear for women. Still further,in some embodiments, the arrangement of apertures on a sole member couldbe varied according to preferences of a user for achieving desiredperformance effects. As an example, a desire for increased flexibilityon a lateral side of the article can be accommodated by increasing thenumber and/or size of apertures on the lateral side of the sole member.In addition, in some embodiments, the configuration of apertures on asole could be varied to achieve various visual or graphical effects.Furthermore, as discussed above, the arrangement of apertures can beindividually customized by measuring various pressure regions of aperson's foot and applying that information to the positioning and typeof apertures on the sole member.

It should be understood that methods of customizing apertureconfiguration for particular sports, gender and/or personal preferencescan be achieved in any manner. In one embodiment, a method ofcustomizing aperture configuration for an article can include provisionsfor allowing a user to select a customized aperture arrangement byinteracting with a website that provides customization tools for varyingthe number and/or geometry of various apertures. Examples of differentcustomization systems that can be used for customizing apertureconfigurations are disclosed in Allen et al., U.S. Patent PublicationNumber 2005/0071242, published Mar. 31, 2005, titled “Method and Systemfor Custom-Manufacturing Footwear,” (previously U.S. patent applicationSer. No. 10/675,237, filed Sep. 30, 2003), and Potter et al., U.S.Patent Publication Number 2004/0024645, published Feb. 5, 2004, titled“Custom Fit Sale of Footwear,” (previously U.S. patent application Ser.No. 10/099,685, filed Mar. 14, 2002) the entirety of both being herebydisclosed by reference. It will be understood that the method ofcustomizing aperture arrangements for an article of footwear are notlimited to use with any particular customization system and in generalany type of customization system known in the art could be used.

Articles of the embodiments discussed herein may be made from materialsknown in the art for making articles of footwear. For example, a solemember may be made from any suitable material, including, but notlimited to: elastomers, siloxanes, natural rubber, other syntheticrubbers, aluminum, steel, natural leather, synthetic leather, foams orplastics. In an exemplary embodiment, materials for a sole member can beselected to enhance the overall flexibility, fit and stability of thearticle. In one embodiment, a foam material can be used with solemember, as foam can provide the desired elasticity and strength. Inanother embodiment, a rubber material could be used to make a midsole ofa sole member. In still another embodiment, a thermoplastic materialcould be used with a sole member. For example, in one embodiment,thermoplastic polyurethane (TPU) may be used to make a midsole for asole member. In still other embodiments, a sole member may comprise amulti-density insert that comprises at least two regions of differingdensities. For example, in one other embodiment, a midsole of a solemember could be configured to receive one or more inserts. Examples ofdifferent types of inserts that could be used are disclosed in Yu etal., U.S. Pat. No. 7,941,938, issued May 17, 2011, titled “Article ofFootwear with Lightweight Sole Assembly,” (previously U.S. patentapplication Ser. No. 11/752,348, filed Mar. 23, 2007) the entirety ofwhich is hereby incorporated by reference. Also, an upper may be madefrom any suitable material known in the art, including, but not limitedto: nylon, natural leather, synthetic leather, natural rubber orsynthetic rubber.

An article of footwear can include provisions for adjusting theflexibility characteristics of a sole member with a plurality ofapertures. In some embodiments, different materials can be used withdifferent portions of a sole. In an exemplary embodiment, portions of asole can be filled with additional material or components to providedifferent types of cushioning, feel, and flexibility for a sole member.For example, in one embodiment, a core portion of a sole member maycomprise a fluid filled member, such as an air bladder. In anotherembodiment, one or more portions of a sole member could include hollowcavities capable of receiving fluid or other materials.

Thus, as described herein, in some embodiments, the arrangement ofapertures on a sole structure could be varied to tune properties of thesole structure for specific types of athletic activities. For example,in some cases, the arrangement of apertures on a sole structure could beselected according to the type of sport for which the article offootwear is intended. In some embodiments, a manufacturer could vary thearrangement of apertures for various types of footwear, including, butnot limited to, soccer footwear, running footwear, cross-trainingfootwear, basketball footwear, as well as other types of footwear.Additionally, in other embodiments, the arrangement of apertures on asole structure could be varied according to the gender of the intendeduser. For example, in some cases, the aperture arrangements may varybetween footwear for men and footwear for women. Still further, in someembodiments, the arrangement of apertures on a sole structure could bevaried according to preferences of a user for achieving desiredperformance effects. As an example, a desire for increased flexibilityon a lateral side of the article can be accommodated by increasing thenumber and/or geometry of apertures on the lateral side of the solestructure. In addition, in some embodiments, the configuration ofapertures on a sole could be varied to achieve various visual orgraphical effects. Furthermore, as discussed above, the arrangement ofapertures can be individually customized by measuring various pressureregions of a person's foot and applying that information to thepositioning and type of apertures on the sole structure.

It should be understood that methods of customizing apertureconfiguration for particular sports, gender and/or personal preferencescan be achieved in any manner. In one embodiment, a method ofcustomizing aperture configuration for an article can include provisionsfor allowing a user to select a customized aperture arrangement byinteracting with a website that provides customization tools for varyingthe number and/or geometry of various apertures. Examples of differentcustomization systems that can be used for customizing apertureconfigurations are disclosed in U.S. Patent Application PublicationNumber 2005/0071242, to Allen, and U.S. Patent Application PublicationNumber 2004/0024645, to Potter et al., the entirety of both being herebydisclosed by reference. It will be understood that the method ofcustomizing aperture arrangements for an article of footwear are notlimited to use with any particular customization system and in generalany type of customization system known in the art could be used.

An article of footwear can include provisions for adjusting theflexibility characteristics of a sole structure with a plurality ofapertures. In some embodiments, different materials can be used withdifferent portions of a sole. In an exemplary embodiment, portions of asole can be filled with additional material or components to providedifferent types of cushioning, feel, and flexibility for a solestructure. For example, in one embodiment, a core portion of a solestructure may comprise a fluid filled member, such as an air bladder. Inanother embodiment, one or more portions of a sole structure couldinclude hollow cavities capable of receiving fluid or other materials.

An embodiment of the sole member production process as described hereinis outlined in the flow chart of FIG. 11. In a first step 1110, apressure distribution of a user's feet is obtained (see FIGS. 5-8above). In other words, the pressure distributions associated with auser's left foot and/or a right foot (i.e., a first foot and a secondfoot) may be obtained. The pressure distributions as well as any otherpreferences are collected to generate a resiliency profile. In a secondstep 1120, the resiliency profile may be used to produce a customconfiguration or pattern of apertures (e.g., position, size, lengths,orientation, etc.) in a sole member. The particular configuration ofapertures generated may be stored in a virtual or digital form in someembodiments. It should be understood that in some embodiments, a firstpattern of apertures may be produced for a left foot, and a secondpattern of apertures may be produced for a corresponding right foot.Following the production of one or more aperture patterns, instructionsto form the apertures in a sole member may be prepared or generated in athird step 1130. In some cases, the aperture pattern may be convertedinto a series of commands or instructions for a system to follow inorder to translate the aperture pattern into mechanical or design stepsfor forming the customized sole member. Finally, in a fourth step 1140,the instructions are executed and a custom sole member is produced. Insome embodiments, the instructions may be executed to produce a firstcustom sole member (e.g., for a left foot) and a complementary secondcustom sole member (e.g., for a right foot).

The process described herein may occur in rapid succession and in closeproximity to one another in some embodiments. However, in otherembodiments, one or more steps may occur spaced apart in time andlocation. In other words, one step may occur in a first location, andanother step may occur in a second location, where the first location isdifferent from the second location. For example, the resiliency profileof first step 1110 may be produced off-site (e.g., at a shopping outletor a medial office, etc.), and the aperture pattern of second step 1120may be produced in a manufacturing facility. In another example, theinstructions for forming the apertures of third step 1130 may beprepared or generated in a local site, while the actual production ofthe custom sole member of fourth step 1140 may occur in a remote site(e.g., out of state, or abroad).

FIG. 12 illustrates another embodiment of a custom sole member for anarticle of footwear. In FIG. 12, an article of footwear 1200 is shown,hereby referred to as article 1200. Article of footwear 1200 can beconfigured as any type of footwear including, but not limited to: hikingboots, soccer shoes, football shoes, sneakers, rugby shoes, basketballshoes, baseball shoes as well as other kinds of footwear. Article 1200can comprise an upper 1202 and a sole structure 1210. Sole structure1210 is secured to upper 1202 and extends between the foot and theground or an outsole when article 1200 is worn. In differentembodiments, sole structure 1210 may include different components. Forexample, sole structure 1210 may include an outsole, a midsole, and/oran insole. In some cases, one or more of these components may beoptional.

Generally, a customized sole member may comprise any layer or element ofsole structure 1210, and be configured as desired. In particular, layersof the sole structure may have any design, shape, size and/or color. Forexample, in embodiments where an article of footwear is a basketballshoe, a sole member could include contours shaped to provide greatersupport to heel prominence. In embodiments where the article of footwearis a running shoe, the custom sole member could be configured withcontours supporting forefoot region 504. In some embodiments, solestructure 1210 could further include provisions for fastening to anupper or another sole layer, and may include still other provisionsfound in footwear sole members. Also, some embodiments of sole structure1210 may include other materials disposed within the custom sole member,such as air bladders, leather, synthetic materials (such as plastic orsynthetic leather), mesh, foam, or a combination thereon.

The material selected for sole structure 1210 or components of solestructure 1210 may possess sufficient durability to withstand therepetitive compressive and bending forces that are generated duringrunning or other athletic activities. In some embodiments, thematerial(s) may include foams, polymers such as urethane or nylon;resins; metals such as aluminum, titanium, stainless steel, orlightweight alloys; or composite materials that combine carbon or glassfibers with a polymer material, ABS plastics, PLA, glass filledpolyamides, stereolithography materials (epoxy resins), silver,titanium, steel, wax, photopolymers and polycarbonate. The customizedsole member may also be formed from a single material or a combinationof different materials. For example, one side of a custom sole membermay be formed from a polymer whereas the opposing side may be formedfrom a foam. In addition, specific regions may be formed from differentmaterials depending upon the anticipated forces experienced by eachregion.

Referring to FIG. 12, an embodiment of completed first custom sole 800in an article of footwear 1200 is shown. Upper 1202 is attached to firstcustom sole 800. As shown in FIG. 12, first custom sole 800 includesapertures 150 of varying sizes arranged throughout lower surface offirst custom sole 800 in regions that may generally correspond to theregions of foot 500 that were indicated to have increased plantarpressures (see FIGS. 5 and 6). In other words, the plantar pressuredistribution comprising pressure contour lines 806 (see FIG. 8) can begenerally aligned with the disposition of apertures 150 in first customsole 800. Thus, in one embodiment, first pressure area 604, secondpressure area 606, third pressure area 608, fourth pressure area 610,and/or fifth pressure area 612 (see FIG. 6) can be accommodated by orcorrespond to different sets of apertures 150 formed in first customsole 800.

Depending on the magnitude of the measured plantar pressures, aperturesin each area can be larger or more numerous. In other words, in areas ofthe foot associated with higher plantar pressures, the number and/orsize of apertures may be increased. For example, in some embodiments,the plantar pressure associated with heel region 508 may be largest. Insuch embodiments, there can be larger apertures disposed in heel region508 relative to other regions of first custom sole 800. In anotherembodiment, the plantar pressure associated with midfoot region 506and/or forefoot region 504 can be greatest. Thus, there may be largerapertures disposed on midfoot region 506 and/or forefoot region 504.

Depending on the magnitude of the measured plantar pressures, aperturesin each area can be larger or more numerous. In other words, in areas ofthe foot associated with higher plantar pressures, the number and/orsize of apertures may be increased. For example, in some embodiments,the plantar pressure associated with heel region 508 may be largest. Insuch embodiments, there can be larger apertures disposed in heel region508 relative to other regions of first custom sole 800.

Thus, in some embodiments, custom sole members as described herein candecrease the plantar pressures acting beneath the forefoot region 504,midfoot region 506, and/or heel region 508, and may help offload areasof higher pressures. A more appropriate type and amount of cushioningcan be generated for a user using the embodiments depicted herein,reducing the amount of pressure experienced by foot 500. For example, ifplantar pressure values are determined to be atypical, the informationcan be used to modify a person's footwear (i.e., the sole member) toprovide the person with footwear more effective in producing a moretypical pattern of foot loading during walking or other activities.

In FIG. 12, an upper surface 1252 is provided on the upper side of firstcustom sole 800, and a lower surface 1254 is provided on the bottom side(i.e., the side that would be facing the ground when worn by a user).Together, upper surface 1252 and lower surface 1254 comprise an exteriorsurface of first custom sole 800. Disposed along various portions of theexterior surface are apertures 150 that extend varying lengths andcomprising varying patterns through thickness 140 (i.e., within aninterior portion) of first custom sole 800. In some embodiments,apertures 150 may be disposed on both upper surface 1252 and lowersurface 1254 of first custom sole 800. In other embodiments, apertures150 may be disposed on only one surface of first custom sole 800. InFIG. 12, apertures 150 are formed along lower surface 1254. More detailsregarding this embodiment are provided in FIGS. 13-15 below.

FIGS. 13-15 provide a series of illustrations of an embodiment of lowersurface 1254 of first custom sole 800 for an article of footwear.Referring to FIG. 13, a first portion 1300 of first custom sole 800comprising a first set of apertures (“first set”) 1302 is shown in anisometric first cutaway view 1392. First portion 1300 comprises aportion of first custom sole 800 that extends from lateral side 510 tomedial side 512. In first set 1302, as best seen in first cutaway view1392, there are six apertures arranged across substantially the entirelateral width of first portion 1300, including a first aperture 1310, asecond aperture 1320, a third aperture 1330, a fourth aperture 1340, afifth aperture 1350, and a sixth aperture 1360. The six aperturescomprising first set 1302 are arranged such that they are generallyaligned along the direction of lateral axis 190.

As noted above, in different embodiments, two or more apertures 150 mayinclude extend through thickness 140 with varying lengths. In someembodiments, the apertures of first set 1302 can extend throughthickness 140 with varying lengths along vertical axis 170. For example,fourth aperture 1340 has a length that is greater than the length offifth aperture 1350. The lengths of each aperture can differ from oneanother, or two or more apertures may have substantially similarlengths. The lengths of the apertures may be selected to providespecific cushioning characteristics.

Furthermore, apertures may comprise varying sizes in differentembodiments. In other words, the average cross-sectional size of eachaperture can be smaller or larger than a neighboring aperture. Forexample, in the embodiment of FIG. 13, each of the apertures of firstset 1302 are associated with a different size relative to one another.Thus, first aperture 1310 has a first size 1313, second aperture 1320has a second size 1322, third aperture 1330 has a third size 1332,fourth aperture 1340 has a fourth size 1342, fifth aperture 1350 has afifth size 1352, and sixth aperture 1360 has a sixth size 1362. Forreference purposes, the sizes identified are associated with thediameter of the aperture; however, in other embodiments, sizes may bemeasured by other parameters, such as interior volume, perimeter, and/orarea.

The magnitude of each aperture size may increase in one direction and/ordecrease in another direction in some embodiments. In other words, theremay be a pattern formed in the sole member related to the size of theadjacent apertures along a direction aligned with lateral axis 190. Inone embodiment, shown in FIG. 13, as apertures of first set 1302approach a first midline 1390 from lateral side 510, the size of eachaperture can increase. In addition, as apertures approach first midline1390 from medial side 512, the size of each aperture can increase. Asshown in first set 1302, first size 1313 is smaller than second size1322, second size 1322 is smaller than third size 1332, and third size1332 is smaller than fourth size 1342. Furthermore, sixth size 1362 issmaller than fifth size 1352, and fifth size 1352 is smaller than fourthsize 1342. Thus, in some cases, the sizes of apertures may oscillate,undulate, taper, fade, or otherwise form a type of pattern. In someembodiments, apertures may generally decrease in size as they approachfirst midline 1390. In one embodiment, apertures may generally increasein size from lateral side 510 to medial side 512. In another embodiment,the apertures may generally decrease in size from lateral side 510 tomedial side 512. It should be understood that references to a midline inthis disclosure is for reference purposes only and the midline may beproximate a center or generally near a center of the sole members.

Furthermore, it should be understood that in other embodiments, two ormore apertures may have diameters or sizes that are substantiallysimilar to one another. For example, first size 1313 and sixth size 1362may be substantially equivalent. In other cases, all apertures of firstset 1302 may have similar sizes. Furthermore, in another embodiment, theapertures may have sizes that are irregular with respect to one another,such that no appreciable pattern is formed.

In some embodiments, a different pattern may be formed. Referring toFIG. 14, a second portion 1400 of first custom sole 800 comprising asecond set of apertures (“second set”) 1402 is shown in an isometricsecond cutaway view 1492. Second portion 1400 comprises a portion offirst custom sole 800 that extends from lateral side 510 to medial side512, similar to first portion 1300 identified in FIG. 13. In second set1402, as best seen in second cutaway view 1492, there are sevenapertures, including a first aperture 1410, a second aperture 1420, athird aperture 1430, a fourth aperture 1440, a fifth aperture 1450, asixth aperture 1460, and a seventh aperture 1470. The seven aperturescomprising second set 1402 are arranged such that they are generallyaligned with lateral axis 190.

As described with respect to FIG. 13, apertures may comprise varyingsizes in different embodiments. In other words, the overall or averagecross-sectional size of each aperture can be smaller or larger than aneighboring aperture. For example, in the embodiment of FIG. 14, severalof the apertures of second set 1402 are associated with a different sizerelative to one another. First aperture 1410 has a first size 1412,second aperture 1420 has a second size 1422, third aperture 1430 has athird size 1432, fourth aperture 1440 has a fourth size 1442, fifthaperture 1450 has a fifth size 1452, sixth aperture 1460 has a sixthsize 1462, and seventh aperture 1470 has a seventh size 1472. Forreference purposes, the sizes identified are associated with thediameter of the aperture; however, in other embodiments, sizes may bemeasured by other parameters, such as interior volume, perimeter, and/orarea.

The magnitude of each aperture size may increase in one direction and/ordecrease in another direction in some embodiments. In other words, theremay be a pattern formed in the sole member related to the size of theadjacent apertures. In one embodiment, shown in FIG. 14, as apertures ofsecond set 1402 approach a second midline 1490 from medial side 512, thesize of each aperture can increase. As shown in second set 1402, seventhsize 1472 is smaller than sixth size 1462, sixth size 1462 is smallerthan fifth size 1452, and fifth size 1452 is smaller than fourth size1442. Fourth size 1442 may be significantly larger than neighboringapertures in second set 1402 in some embodiments.

However, it should be understood that in other embodiments, two or moreapertures may have diameters or sizes that are substantially similar toone another. For example, first size 1412 and second size 1422 aresubstantially equivalent in FIG. 14. In other cases, one or moreapertures of second set 1402 disposed on medial side 512 relative tofirst midline 1390 may have similar sizes. In another embodiment, one ormore apertures of second set 1402 disposed on lateral side 510 relativeto first midline 1390 may have similar sizes.

In some embodiments, there may be apertures formed in directions alignedwith other orientations or have a different arrangement. In FIG. 15, athird portion 1500 is depicted an isometric third cutaway view 1592.Third portion 1500 has a third set of apertures (“third set”) 1502disposed over substantially the entire longitudinal length of lowersurface 1254 of third portion 1500, extending from forefoot region 504to heel region 508.

Specifically referring to FIG. 15, in third set 1502 (as best seen inthird cutaway view 1592), there are 25 apertures, including a firstaperture 1511, a second aperture 1512, a third aperture 1513, a fourthaperture 1514, a fifth aperture 1515, a sixth aperture 1516, a seventhaperture 1517, an eighth aperture 1518, a ninth aperture 1519, a tenthaperture 1520, an eleventh aperture 1521, a twelfth aperture 1522, athirteenth aperture 1523, a fourteenth aperture 1524, a fifteenthaperture 1525, a sixteenth aperture 1526, a seventeenth aperture 1527,an eighteenth aperture 1528, a nineteenth aperture 1529, a twentiethaperture 1530, a twenty-first aperture 1531, a twenty-second aperture1532, a twenty-third aperture 1533, a twenty-fourth aperture 1534, and atwenty-fifth aperture 1535. The 25 apertures comprising third set 1502are arranged such that they are generally extending in the directionassociated with longitudinal axis 180.

Furthermore, apertures may comprise varying sizes in differentembodiments. In other words, the overall or average cross-sectional sizeof each aperture can be smaller or larger than a neighboring aperture.For example, in the embodiment of FIG. 15, several of the apertures ofthird set 1502 are associated with a different size relative to oneanother. Thus, first aperture 1511 has a first size 1561, secondaperture 1512 has a second size 1562, third aperture 1513 has a thirdsize 1563, fourth aperture 1514 has a fourth size 1564, fifth aperture1515 has a fifth size 1565, sixth aperture 1516 has a sixth size 1566,seventh aperture 1517 has a seventh size 1567, eighth aperture 1518 hasan eighth size 1568, ninth aperture 1519 has a ninth size 1569, tenthaperture 1520 has a tenth size 1570, eleventh aperture 1521 has aneleventh size 1571, twelfth aperture 1522 has a twelfth size 1572, andthirteenth aperture 1523 has a thirteenth size 1573. In addition,fourteenth aperture 1524 has a fourteenth size 1574, fifteenth aperture1525 has a fifteenth size 1575, sixteenth aperture 1526 has a sixteenthsize 1576, seventeenth aperture 1527 has a seventeenth size 1577,eighteenth aperture 1528 has an eighteenth size 1578, nineteenthaperture 1529 has a nineteenth size 1579, twentieth aperture 1530 has atwentieth size 1580, twenty-first aperture 1531 has a twenty-first size1581, twenty-second aperture 1532 has a twenty-second size 1582,twenty-third aperture 1533 has a twenty-third size 1583, twenty-fourthaperture 1534 has a twenty-fourth size 1584, and twenty-fifth aperture1535 has a twenty-fifth size 1585. For reference purposes, the sizesidentified are associated with the diameter of the aperture; however, inother embodiments, sizes may be measured by other parameters, such asinterior volume, perimeter, and/or area.

As seen in FIG. 15, at least some of the apertures in third set 1502 arearranged in a generally oscillating pattern, such that the size of eachaperture gradually increases as the apertures approach a third midline1590, and then decrease or taper toward zero as the apertures approachan edge. As noted above, apertures 150 may be arranged in a geometricpattern to provide a wearer with enhanced or improved support andcushioning, and such an oscillating pattern may improve the comfort andfeel of the sole member for a foot.

In other words, the magnitude of each aperture size may increase in onedirection and/or decrease in another direction in some embodiments.Thus, there may be a pattern formed in the sole member in a directiongenerally aligned with longitudinal axis 180 based on thecross-sectional size of the adjacent apertures. In other embodiments,there may be a curvature (i.e., non-linear) to the arrangement of acolumn of apertures that extend from heel region 508 to forefoot region504. Thus, the use of the label “column” should be understood to referto an arrangement of apertures that that are adjacent to one another ina general direction extending from heel region 508 to forefoot region504, rather than necessarily being aligned in a straight or undeviatingarrangement.

In one embodiment, shown in FIG. 15, as apertures of third set 1502approach second midline 1390 from heel region 508, the size of eachaperture can increase. In addition, as apertures approach third midline1590 from forefoot region 504, the size of each aperture can increase.

Some examples of different patterns can be seen in FIG. 15. As shown inthird set 1502, beginning in forefoot region 504, fifth size 1565 issmaller than sixth size 1566, sixth size 1566 is smaller than seventhsize 1567, seventh size 1567 is smaller than eighth size 1568, eighthsize 1568 is smaller than ninth size 1569, and ninth size 1569 issmaller than tenth size 1570. Similarly, beginning in heel region 508,twenty-fifth size 1585 is smaller than twenty-fourth size 1584,twenty-fourth size 1584 is smaller than twenty-third size 1583, andtwenty-third size 1583 is smaller than twenty-second size 1582. Inaddition, fifteenth size 1575 is smaller than fourteenth size 1574, andfourteenth size 1574 is smaller than thirteenth size 1573.

Thus, in some embodiments, the sizes of apertures may oscillate,undulate, taper, fade, or otherwise form a type of pattern. In otherembodiments, apertures may generally decrease in size as they approachthird midline 1590. In one embodiment, apertures may generally increasein size from forefoot region 504 to heel region 508. In anotherembodiment, the apertures may generally decrease in size from forefootregion 504 to heel region 508.

However, it should be understood that in other embodiments, two or moreapertures may have diameters or sizes that are substantially similar toone another. For example, twenty-first size 1581, twentieth size 1580,nineteenth size 1579, eighteenth size 1578, seventeenth size 1577, andsixteenth size 1576 may be substantially equivalent. In other cases, allapertures of third set 1502 may have similar sizes. In otherembodiments, two or more apertures of third set 1502 disposed towardheel region 508 relative to third midline 1590 may have similar sizes.In another embodiment, two or more apertures of third set 1502 disposedtoward forefoot region 504 relative to third midline 1590 may havesimilar sizes.

Furthermore, in another embodiment, the apertures may have sizes thatare irregular with respect to one another, such that no appreciablepattern is formed. In other words, at least some of the apertures inthird set 1502 can be arranged in an irregular fashion with respect toaperture size.

As noted above, aperture depths and/or sizes may be configured toperform specialized or customized support and cushioning. Thus, thesizes of apertures 150 may be selected and/or formed to providecustomized support for an individual foot. In different embodiments, asshown in FIGS. 13-15, first custom sole 800 can provide both generalizedcushioning, as well as specialized (i.e., uniquely tailored) cushioning.

FIG. 16 illustrates an embodiment of lower surface 1254 of a secondcustom sole 1600. Referring to FIG. 16, a fourth portion 1608 of secondcustom sole 1600 comprising a fourth set of apertures (“fourth set”)1602 is shown in an isometric fourth cutaway view 1692. Fourth portion1608 comprises a portion of second custom sole 1600 that generallyextends from lateral side 510 to medial side 512. In the exampleprovided by fourth set 1602 (as best seen in fourth cutaway view 1692),there are six apertures arranged across substantially the entire lateralwidth of fourth portion 1608 including a first aperture 1610, a secondaperture 1620, a third aperture 1630, a fourth aperture 1640, a fifthaperture 1650, and a sixth aperture 1660. Similar to the embodiment offirst set 1302 in FIG. 13, the six apertures comprising fourth set 1602in FIG. 16 are arranged in a direction generally aligned with lateralaxis 190.

Furthermore, apertures may comprise varying sizes in differentembodiments. In other words, the overall or average cross-sectional sizeof each aperture can be smaller or larger than a neighboring aperture.For example, in the embodiment of FIG. 16, several of the apertures offourth set 1602 are associated with a different size relative to oneanother. In FIG. 16, first aperture 1610 has a first size 1612, secondaperture 1620 has a second size 1622, third aperture 1630 has a thirdsize 1632, fourth aperture 1640 has a fourth size 1642, fifth aperture1650 has a fifth size 1652, and sixth aperture 1660 has a sixth size1662.

As described with respect to FIGS. 13-15, the magnitude of each aperturesize may increase in one direction and/or decrease in another directionin some embodiments. In other words, there may be a pattern formed inthe sole member related to the size of the adjacent apertures in adirection generally aligned with lateral axis 190 and/or longitudinalaxis 180. For example, as apertures of fourth set 1602 approach a fourthmidline 1690 from lateral side 510, the size of each aperture canincrease. In addition, as apertures approach fourth midline 1690 frommedial side 512, the size of each aperture can increase. As shown infourth set 1602, first size 1612 is smaller than second size 1622,second size 1622 is smaller than third size 1632, and third size 1632 issmaller than fourth size 1642. Furthermore, sixth size 1662 is smallerthan fifth size 1652, and fifth size 1652 is smaller than fourth size1642. Thus, in some cases, the sizes of apertures may oscillate,undulate, taper, fade, or otherwise form a type of pattern. In someembodiments, apertures may generally decrease in size as they approachfourth midline 1690. In one embodiment, apertures may generally increasein size from lateral side 510 to medial side 512. In another embodiment,the apertures may generally decrease in size from lateral side 510 tomedial side 512.

However, it should be understood that in other embodiments, two or moreapertures may have diameters or sizes that are substantially similar toone another. For example, second size 1622 and fifth size 1652 may besubstantially equivalent. In other cases, all apertures of fourth set1602 may have similar sizes. Furthermore, in another embodiment, theapertures may have sizes that are irregular with respect to one another,such that no appreciable pattern is formed.

In addition, two or more apertures may be disposed at differentdistances from one another. For example, in one embodiment, firstaperture 1610 is disposed such that it is distinct and separate fromsecond aperture 1620. However, third aperture 1630 and fourth aperture1640 are disposed such that they adjoin one another, and have mergedboundaries. In other words, two apertures can approach, touch and/ormerge with one another. Thus, in some embodiments, two or more aperturesmay be disposed close enough to one another so as to form asubstantially continuous opening similar to a siping. In someembodiments, the distance between two apertures may be approximatelyzero. In different embodiments, a feature similar to a siping can be aresult of the varying degrees of merging between adjoining apertures. Insome embodiments, apertures may be formed in various portions of acushioning element to create a siping-like region, groove, or channel,through the cushioning element. While the arrangement can providevariations in cushioning, there may be other benefits, includingenhanced traction or grip of the exterior surface. Various designs orflexible regions may also be formed by the inclusion of such sipedapertures.

Furthermore, as noted above, in different embodiments, apertures 150 mayextend through thickness 140 with varying lengths or depths. In theembodiment of FIG. 16, fourth portion 1608 includes apertures thatextend through thickness 140 with depths that vary in a verticaldirection relative to other apertures. However, in some embodiments,there may be differences in depth within a single aperture. In otherwords, a single aperture may include a “step”, or different levelportions that are associated with different depths. For example,referring to FIG. 17, an isolated view of the portion of second customsole 1600 that includes fifth aperture 1650 is illustrated. Fifthaperture 1650 can be seen to include a first portion 1710 and a secondportion 1720. First portion 1720 has a base 1750 that extends a firstdistance from lower surface 1254, where the first distance can vary inlength. In addition, there is a smaller sub-aperture 1770 disposedwithin base 1750 that is associated with second portion 1720.Sub-aperture 1770 can extend various depths through the interior portionof second custom sole 1600.

Referring now to FIG. 18, a cross-section of fifth aperture 1650 isdepicted. It can be seen that fifth aperture 1650 has a first depth 1810associated with first portion 1710, and a second depth 1820 associatedwith second portion 1720. In some embodiments, first depth 1810 may bemore shallow (i.e., less deep) than second depth 1820. In FIG. 17, firstdepth 1810 forms an outer boundary or ledge (similar to a step) betweensecond depth 1820 and lower surface 1254. For purposes of thisdisclosure, fifth aperture 1650 may be referred to as including two“levels”, where each level is associated with the different depthprovided within the aperture. It should be understood that first depth1810 may be greater than, less than, or substantially similar to seconddepth 1820 in different embodiments. In FIG. 18, first depth 1810 isless than second depth 1820.

Thus, in some embodiments, apertures may include various depth levelswithin a single aperture. In other embodiments, fifth aperture 1650 mayinclude multiple depth levels, beyond those illustrated in FIGS. 16-18.For example, fifth aperture 1650 may include three, four, or fivelevels.

It should be understood that, in some embodiments, each level may alsoinclude a corresponding cross-sectional size that differs from thecross-sectional size of an adjacent level. For example, referring againto fifth aperture 1650 in FIG. 18, first portion 1710 can be associatedwith first size 1860, and second portion 1720 can be associated with asecond size 1870. In different embodiments, first size 1860 may begreater than, less than, or substantially similar to second size 1870.In FIG. 18, first size 1860 is greater than second size 1870.

In some embodiments, apertures 150 may be arranged to form regular rowsalong first custom sole 800. As shown in FIG. 12-16, there are 25 rowsof apertures, and eight columns of apertures. In other embodiments,there may be less than or greater than 25 rows, and/or less than orgreater than eight columns. For purposes of this disclosure, rows and/orcolumns need not be linear, and may comprise curving areas where theneighboring apertures in a column or row are generally aligned but maybe offset from one another. For example, first set 1302 comprises a rowof apertures, and third set 1502 comprises a column of apertures. Eachrow and column can include a different number of apertures than shownhere (i.e., more than or less than 6 rows and/or more than or less than25 columns).

In different embodiments, each size of the apertures may be similar ormay differ from that depicted here. For example, in other embodiments,first aperture 1310 may be larger than fourth aperture 1340. Thus, insome embodiments, apertures 150 disposed on first custom sole 800 canhave varying sizes with respect to one another, or they may have thesame size. Furthermore, apertures 150 may vary with respect to oneanother in shape, or the shapes may each be the same. In otherembodiments, apertures 150 may differ from one another in both size andshape along the same surface.

FIG. 19 illustrates an embodiment of lower surface 1254 of a thirdcustom sole 1900. Referring to FIG. 19, a fifth portion 1908 of thirdcustom sole 1900 comprising a fifth set of apertures (“fifth set”) 1902is shown in a magnified view 1992. Fifth portion 1908 comprises aportion of third custom sole 1900 that generally extends from lateralside 510 to medial side 512. In the example provided by fifth set 1902(as best seen in magnified view 1992), there are a plurality ofapertures arranged across substantially the entire lateral width offifth portion 1908. The apertures are disposed at varying densitydistributions, including a first distribution 1910, a seconddistribution 1920, and a third distribution 1930. For purposes of thisdisclosure, density distribution, or distribution, refers to the averagepopulation of apertures per unit area or unit volume of the cushioningelement. In other words, regions of third custom sole 1900 with a higherdensity will have a greater number of apertures disposed closer togetherthan regions with a lower density. In some embodiments, aperturesdisposed more proximate to a longitudinal midline of the sole member maybe generally arranged more closer together (i.e., in a more densedistribution) than apertures disposed further away from the longitudinalmidline.

In different embodiments, as noted above, two or more apertures may bedisposed at different distances from one another. For example, in oneembodiment, apertures in the region associated with first distribution1910 may be disposed on average more proximate to one another thanapertures in the region associated with second distribution 1920.Furthermore, apertures in the region associated with second distribution1920 may be disposed on average more proximate to one another thanapertures in the region associated with third distribution 1930.

In different embodiments, one or more of the apertures described withrespect to FIG. 19 may vary in size. In some embodiments at least someof the apertures may be smaller relative to the apertures of theembodiments described with respect to FIGS. 12-18. Thus, in someembodiments, one or more apertures may be between 0 and 5 millimeters indiameter. In other embodiments, one or more apertures may be between 0and 2 millimeters in diameter. In one embodiment, a majority of theapertures may be less than 2 millimeters in diameter. In some cases, amajority or all of the apertures may be less than 1 millimeter indiameter. In other words, one or more apertures may be a “pinpoint” sizein some embodiments, such that the depth and/or diameter of the apertureis very small relative to the sole member outer surface area.

In some embodiments, two or more apertures may be disposed such thatthey adjoin one another, and have merged boundaries. In other words, twoapertures can approach, touch and/or merge with one another. Thus, insome embodiments, two or more apertures may be disposed close enough toone another so as to form a substantially continuous opening similar toa siping. In different embodiments, a siping facsimile can be a resultof the varying degrees of merging between adjoining apertures. In someembodiments, the distance between two apertures may be approximatelyzero. In some embodiments, apertures may be formed in various portionsof a cushioning element to create a siping-like region, groove, orchannel, through the cushioning element. While the arrangement canprovide variations in cushioning, there may be other benefits, includingenhanced traction or grip of the exterior surface. Various designs orflexible regions may also be formed by the inclusion of such sipedapertures. Thus, referring to third custom sole 1900, apertures may bedisposed along various regions or portions of the sole such that varyingdistribution patterns are formed. In some embodiments, cushioningcharacteristics may be adjusted or customized based on the density ofapertures included in different areas of third custom sole 1900.

As discussed in FIGS. 12-19, it can be seen that the number of aperturesincluded in a sole member can vary. In some embodiments, apertures cancomprise between 5% and 20% of lower surface 1254 of a sole member. Inother embodiments, apertures can comprise between 10% and 30% of lowersurface 1254 of a sole member. In different embodiments, apertures cancomprise between 15% and 50% of lower surface 1254 of a sole member. Inone embodiment, apertures can comprise over 50% of lower surface 1254 ofa sole member.

Specifically referring to the illustrative embodiments of FIGS. 12-15,it can be seen that in some cases, apertures 150 can comprise at least15% of lower surface 1254 of first custom sole 800. In FIG. 16, it canbe seen that in other cases apertures 150 can comprise at least 30% oflower surface 1254 of second custom sole 1600. Furthermore, referring toFIG. 19, in some cases apertures 150 can comprise at least 45% of lowersurface 1254 of third custom sole 1900.

Thus, the various cushioning elements as described here can provide acustom sole member with specialized responses to ground reaction forces.In one embodiment, the cushioning element may attenuate and distributesground reaction forces. For example, when a portion of the custom solemember contacts the ground, the apertures disposed in cushioning elementcan help attenuate the ground reaction forces. The cushioning elementmay have the capacity to distribute the ground reaction forcesthroughout a substantial portion of the custom sole member. Theattenuating property of this type of structure can reduce the degree ofthe effect that ground reaction forces have on the foot, and thedistributive property distributes the ground reaction forces to variousportions of a foot. In some embodiments, such features may reduce thepeak ground reaction force experienced by the foot.

In other embodiments, the cushioning element designs disclosed in thisdescription may also include provisions to achieve a non-uniform groundreaction force distribution. For example, the ground reaction forcedistribution of a custom sole member could provide a wearer with aresponse similar to that of barefoot running, but with attenuated groundreaction forces. That is, the custom sole member could be designed toimpart the feeling of barefoot running, but with a reduced level ofground reaction forces. Additionally, in another example, the groundreaction forces could be more concentrated in the medial side of a footthan along a lateral side of a foot, thereby reducing the probabilitythat the foot will over-pronate, or imparting greater resistance toeversion and inversion of the foot.

In some embodiments, the use of cushioning elements in orthotics for anarticle of footwear can help support weakened areas of the foot andassist the user in each step. While a relatively rigid material, as maybe included in a custom sole member, can provide functional support tothe foot, softer or more flexible regions associated with apertures canabsorb the loads put on the foot and provide protection. Such softer orcushioned regions can better absorb the loads placed on a foot, increasestabilization, and take pressure off uncomfortable or sore spots of thefeet.

Other embodiments or variations of custom sole members may include otherlattice structure designs or various combinations of the above-discloseddesigns. It should be noted that the present description is not limitedto cushioning elements having the geometry or aperture configurations offirst custom sole 800, second custom sole 1600, and third custom sole1900. In different embodiments, each customized sole member may includefurther variations not depicted in the figures. Some variations mayinclude differences in shape, size, contour, elevations, depressions,curvatures, and other variations. In other words, the custom solemembers depicted herein are merely intended to provide an example of themany types of cushioning element-based sole member configurations thatfall within the scope of the present discussion.

In different embodiments, sole members as well as any apertures in thesole members discussed herein may be formed using any other method knownin the art. In some embodiments, any removal process (i.e., where aportion of a material is removed, subtracted, eliminated, etc.) may beused to form one or more apertures (e.g., apertures 150). For example,in some embodiments, a mechanical process may be used, including but notlimited to ultrasonic machining, water jet machining, abrasive jetmachining, abrasive water jet machining, ice jet machining, and/ormagnetic abrasive finishing. In other embodiments, chemical processesmay be utilized, including but not limited to chemical milling,photochemical milling, and/or eletropolishing. Furthermore, in someembodiments, electrochemical processes may be used. In otherembodiments, thermal processes can be used, such as electrodischargemachining (EDM), laser beam machining, electron beam machining, plasmabeam machining, and/or ion beam machining, or other processes. Inanother embodiment, hybrid electrochemical processes can be utilized,including but not limited to electrochemical grinding, electrochemicalhoning, electrochemical superfinishing, and/or electrochemical buffing.In addition, hybrid thermal processes may be used, such aselectroerosion dissolution machining. In other embodiments, the materialcomprising the sole member may be modified using chemical processes,including temperature changes (e.g., freezing the material).Furthermore, the processes for forming the apertures may be applied orutilized after the article of footwear has been assembled, or the solemember has been associated with an upper or sole structure. In otherwords, the formation of apertures in a sole member may occurpost-manufacturing of the article of footwear.

It should be understood that in other embodiments, the midsole caninclude a casing in a molded foam. In other words, embodiments of thesole member as described herein may be associated with the midsole of asole structure. Thus, in some embodiments, a midsole may include a foammaterial. The foam material can comprise a ‘skin’ surface that is formedfrom a molding process. In some embodiments, the various removalprocesses described above (e.g., drilling, laser, chemical, EDM, watercutting, etc.) can be applied to the foam skin of a midsole andapertures can be formed in a manner similar to the embodiments discussedabove.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Although many possible combinations of features are shownin the accompanying figures and discussed in this detailed description,many other combinations of the disclosed features are possible. Anyfeature of any embodiment may be used in combination with or substitutedfor any other feature or element in any other embodiment unlessspecifically restricted. Therefore, it will be understood that any ofthe features shown and/or discussed in the present disclosure may beimplemented together in any suitable combination. Accordingly, theembodiments are not to be restricted except in light of the attachedclaims and their equivalents. Also, various modifications and changesmay be made within the scope of the attached claims.

What is claimed is:
 1. A sole member for an article of footwear,comprising: a sole member, the sole member including an outer surface,the outer surface comprising an upper surface and a lower surface; thesole member having an interior portion, wherein the interior portion isdisposed between the upper surface and the lower surface; the solemember having a forefoot region and a heel region; the sole memberhaving a set of apertures, wherein at least one aperture of the set ofapertures is a blind-hole aperture; wherein each aperture of the set ofapertures is disposed along a portion of the outer surface of the solemember; wherein each aperture of the set of apertures has across-sectional diameter; wherein at least a portion of the set ofapertures is arranged along the outer surface of the sole member tocomprise a first column of apertures formed of apertures adjacent oneanother in a direction extending from the heel region to the forefootregion of the sole member; wherein the first column of apertures extendscontinuously from the forefoot region to the heel region; wherein thefirst column of apertures includes at least a first aperture, a secondaperture disposed adjacent to the first aperture, and a third aperturedisposed adjacent to the second aperture, and wherein the first aperturehas a first cross-sectional diameter, the second aperture has a secondcross-sectional diameter, and the third aperture has a thirdcross-sectional diameter; wherein the first cross-sectional diameter issmaller than the second cross-sectional diameter, and wherein the secondcross-sectional diameter is smaller than the third cross-sectionaldiameter; and wherein the cross-sectional diameters of the apertures ofthe first column of apertures continuously increase from the forefootregion to a center of the sole member located in a midfoot region of thesole member, and wherein the cross-sectional diameters of the aperturesof the first column of apertures continuously decrease from the centerof the sole member to the heel region.
 2. The sole member of claim 1,wherein the first column of apertures is curved from the forefoot regionto the heel region.
 3. The sole member of claim 1, wherein the firstaperture is oriented in a substantially vertical direction, wherein thevertical direction extends between the upper surface and the lowersurface of the sole member.
 4. The sole member of claim 1, wherein eachaperture of the set of apertures has a length extending through aportion of the interior portion of the sole member, and wherein thelength of each aperture of the set of apertures is substantiallysimilar.
 5. The sole member of claim 1, the sole member having a lateralside and a medial side, wherein at least a portion of the set ofapertures are arranged along the outer surface of the sole member tocomprise a first row of apertures, wherein the first row of aperturesextends from the lateral side to the medial side.
 6. The sole member ofclaim 5, wherein the first row of apertures includes a fourth aperture,and wherein the fourth aperture is the same as the third aperture of thefirst column.
 7. The sole member of claim 5, wherein the first row ofapertures includes at least a fourth aperture, a fifth aperture disposedadjacent to the fourth aperture, and a sixth aperture disposed adjacentto the fifth aperture, and wherein the fourth aperture has a fourthcross-sectional diameter, the fifth aperture has a fifth cross-sectionaldiameter, and the sixth aperture has a sixth cross-sectional diameter,and wherein the fourth cross-sectional diameter is smaller than thefifth cross-sectional diameter, and wherein the fifth cross-sectionaldiameter is smaller than the sixth cross-sectional diameter.
 8. The solemember of claim 5, wherein the cross-sectional diameters of theapertures of the first row of apertures increase continuously from thelateral side of the sole member to a center of the first row ofapertures, and wherein the cross-sectional diameters of the apertures ofthe first row of apertures increase continuously from the medial side ofthe sole member to the center of the first row of apertures.
 9. The solemember of claim 1, further comprising a second column of apertures, andwherein the second column of apertures extends from the forefoot regionto the heel region of the sole member.
 10. A sole member for an articleof footwear, comprising: a sole member, the sole member including anouter surface, the outer surface comprising an upper surface and a lowersurface; the sole member having a forefoot region and a heel region; thesole member having a set of apertures, wherein each aperture of the setof apertures is a blind-hole aperture; wherein at least a portion of theset of apertures is disposed along a portion of the outer surface of thesole member to form a first column of apertures formed of aperturesadjacent one another in a direction extending from the heel region tothe forefoot region of the sole member; wherein the first column ofapertures extends continuously from the forefoot region to the heelregion; wherein each aperture of the set of apertures has across-sectional diameter; wherein a size of a majority of the aperturescomprising the first column of apertures generally increases in adirection approaching a midfoot region of the sole member; and whereinthe cross-sectional diameters of the apertures of the first column ofapertures continuously increase from the forefoot region to a center ofthe sole member located in the midfoot region of the sole member, andwherein the cross-sectional diameters of the apertures of the firstcolumn of apertures continuously decrease from the center of the solemember to the heel region.
 11. The sole member of claim 10, furthercomprising a second column of apertures, wherein the second column ofapertures extends continuously from the forefoot region to the heelregion.
 12. The sole member of claim 10, wherein the first column ofapertures includes at least twelve apertures.
 13. The sole member ofclaim 10, wherein the first column of apertures includes a firstaperture, wherein the first aperture includes a first portion and asecond portion, wherein the first portion has a first diameter, whereinthe second portion has a second diameter, and wherein the first diameteris greater than the second diameter.
 14. The sole member of claim 13,wherein the first column of apertures includes a first aperture, whereinthe first aperture includes a first portion and a second portion,wherein the first portion has a first length, wherein the second portionhas a second length, and wherein first length is less than secondlength.
 15. The sole member of claim 13, wherein the first portion ismore proximate to the lower surface of the sole member than the secondportion.
 16. The sole member of claim 13, wherein the first column ofapertures further includes a second aperture disposed adjacent to thefirst aperture, and wherein a distance between the first aperture andthe second aperture is approximately zero, forming a siping-like regionin the sole member.
 17. The sole member of claim 10, wherein the firstcolumn of apertures is curved from the forefoot region to the heelregion of the sole member.
 18. The sole member of claim 10, wherein theset of apertures further includes a first row of apertures comprisingapertures arranged from a medial side to a lateral side of the solemember, wherein the cross-sectional diameters of the apertures of thefirst row of apertures increase continuously from the lateral side ofthe sole member to a center of the first row of apertures, and whereinthe cross-sectional diameters of the apertures of the first row ofapertures increase continuously from the medial side of the sole memberto the center of the first row of apertures.
 19. A sole member for anarticle of footwear, comprising: a sole structure formed of a foammaterial and including a forefoot region, a midfoot region, and a heelregion, wherein the sole structure includes: (a) an outer surface havingan upper surface and a lower surface, and (b) an interior portiondisposed between the upper surface and the lower surface; and a set ofapertures defined in the outer surface of the sole structure andextending into the foam material, wherein at least one aperture of theset of apertures is a blind-hole aperture extending into the foammaterial, wherein at least a portion of the set of apertures is arrangedalong the outer surface of the sole structure to comprise a first columnof apertures formed of apertures adjacent one another and extendingcontinuously from the heel region, through the midfoot region, and tothe forefoot region of the sole structure, wherein cross-sectionaldiameters of the apertures of the first column of apertures continuouslyincrease from the forefoot region to a center of the sole structurelocated in the midfoot region of the sole structure, and wherein thecross-sectional diameters of the apertures of the first column ofapertures continuously decrease from the center of the sole structure tothe heel region.
 20. The sole member of claim 19, wherein a majority ofthe apertures of the set of apertures are less than 2 millimeters indiameter.
 21. The sole member of claim 19, wherein the set of aperturesfurther includes a first row of apertures extending from a lateral sideof the sole structure to a medial side of the sole structure, whereincross-sectional diameters of the apertures of the first row of aperturesincrease continuously from the lateral side of the sole structure to acenter of the first row of apertures, and wherein the cross-sectionaldiameters of the apertures of the first row of apertures increasecontinuously from the medial side of the sole structure to the center ofthe first row of apertures.
 22. The sole member of claim 19, wherein thefirst column of apertures is curved from the forefoot region to the heelregion of the sole structure.
 23. The sole member of claim 21, whereinone aperture of the first row of apertures also is an aperture in thefirst column of apertures.
 24. The sole member of claim 19, wherein theset of apertures further includes a plurality of longitudinally spacedrows of apertures extending from a lateral side of the sole structure toa medial side of the sole structure throughout the midfoot region of thesole structure.
 25. The sole member of claim 19, wherein the solestructure is formed of a single material.
 26. A sole member for anarticle of footwear, consisting essentially of: a sole structure formedof a foam material and including a forefoot region, a midfoot region,and a heel region, wherein the sole structure includes: (a) an outersurface having an upper surface and a lower surface, and (b) an interiorportion disposed between the upper surface and the lower surface; and aset of apertures defined in the outer surface of the sole structure andextending into the foam material, wherein at least one aperture of theset of apertures is a blind-hole aperture extending into the foammaterial, wherein at least a portion of the set of apertures is arrangedalong the outer surface of the sole structure to comprise a first columnof apertures formed of apertures adjacent one another and extendingcontinuously from the heel region, through the midfoot region, and tothe forefoot region of the sole structure, wherein cross-sectionaldiameters of the apertures of the first column of apertures continuouslyincrease from the forefoot region to a center of the sole structurelocated in the midfoot region of the sole structure, and wherein thecross-sectional diameters of the apertures of the first column ofapertures continuously decrease from the center of the sole structure tothe heel region.
 27. The sole member of claim 26, wherein the set ofapertures further includes a first row of apertures extending from alateral side of the sole structure to a medial side of the solestructure, wherein cross-sectional diameters of the apertures of thefirst row of apertures increase continuously from the lateral side ofthe sole structure to a center of the first row of apertures, andwherein the cross-sectional diameters of the apertures of the first rowof apertures increase continuously from the medial side of the solestructure to the center of the first row of apertures.
 28. The solemember of claim 26, wherein the set of apertures further includes aplurality of longitudinally spaced rows of apertures extending from alateral side of the sole structure to a medial side of the solestructure throughout the midfoot region of the sole structure.